Description

Abaco Systems VMIPCI-5565-110000

I. Overview

The Abaco Systems VMIPCI-5565-110000 is a high-performance PCI-interface industrial motion control card, specifically designed for high-precision multi-axis motion control scenarios. Serving as a core control bridge between upper computers, servo drives, and stepper motor drives, it enables precise planning, real-time control, and status monitoring of multi-axis motion. This product is widely used in fields with strict requirements for motion control accuracy and response speed, such as CNC machine tools, robotic automation, electronic manufacturing equipment (e.g., semiconductor packaging, PCB drilling machines), laser processing equipment, and automated production lines.

II. Technical Parameters

III. Functional Features

• Multi-Axis High-Precision Synchronous Control: Supports 8-axis independent or synchronous motion control, with linear interpolation (up to 8 axes), circular interpolation (2 axes), and continuous path control functions. The interpolation accuracy reaches ±0.001 pulses, enabling precise implementation of complex trajectory motion. Built-in electronic cam and electronic gearing functions: the electronic cam supports customization of 1024-point cam curves, and the electronic gear ratio can be adjusted in real time (range: 1:1000 to 1000:1), adapting to scenarios such as assembly line synchronous transmission and cam profiling processing.
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• High-Speed Pulse Output & Feedback Closed-Loop: The maximum pulse output frequency per axis is up to 2MHz, and it can still reach 1MHz when 8 axes output synchronously, enabling driving of high-speed servo or stepper motors for rapid positioning. Equipped with 8 high-speed position feedback input channels, it supports incremental encoders (max. 5MHz input) and optional absolute encoders. By collecting motor position information in real time, it forms closed-loop position control, effectively suppressing positioning errors caused by load changes. The positioning accuracy depends on the encoder resolution, supporting up to 16-bit absolute encoders.
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• Rich Motion Control Functions: Supports multiple motion modes, including point-to-point motion (configurable acceleration/deceleration curves, target position, speed), Jog motion (manual jogging with adjustable speed), profile motion (operation along preset trajectories), and trigger motion (motion activation via digital input or software commands). It features motion interruption and emergency stop processing functions, with an emergency stop signal response time ≤1ms, which can quickly cut off motion output to ensure equipment and personnel safety.
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• Strong Anti-Interference & High-Reliability Design: Digital I/O and position feedback inputs adopt optical isolation design with an isolation voltage of 2500V AC, effectively preventing the impact of strong electrical interference in industrial sites on control signals. Pulse output uses differential signals, and long-distance transmission (max. 50 meters) can be achieved with shielded cables, reducing signal attenuation and crosstalk. Industrial-grade components and enhanced PCB layout are used, with overvoltage and overcurrent protection functions, and the Mean Time Between Failures (MTBF) is ≥150,000 hours.
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• Convenient Development & Debugging Support: Provides a motion control software development kit (SDK) for Windows and Linux systems, including function libraries and sample codes for multiple programming languages such as C/C++ and C# , supporting users to quickly develop custom motion control programs. The on-board JTAG debugging interface and RS232 configuration interface allow real-time monitoring of axis motion status, pulse output frequency, feedback position, and other parameters through dedicated debugging software, supporting online modification of motion parameters and fault diagnosis.
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• Flexible I/O Expansion & Integration: Equipped with 16-channel isolated digital inputs and 16-channel isolated digital outputs, it can directly connect to peripheral devices such as limit switches, emergency stop buttons, solenoid valves, and indicator lights without additional I/O modules. It supports data interaction with devices such as PLCs and HMIs through industrial computers, and motion control programs can be seamlessly integrated with upper computer monitoring systems to realize functions such as real-time motion status display, parameter setting, and fault alarm.

IV. Working Principle

1. Initialization & Command Reception Stage: After the control card is inserted into the PCI slot of the industrial computer, hardware initialization is completed via the PCI bus. The upper computer sends initialization parameters (such as axis number assignment, pulse output mode, feedback type, and acceleration/deceleration curve parameters) to the control card through the motion control SDK. During operation, the upper computer sends motion commands (such as target position and speed for point-to-point motion, and trajectory point coordinates for interpolation motion), which are transmitted to the embedded processor of the control card via the PCI bus.
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3. Trajectory Planning & Pulse Generation Stage: After receiving the motion commands, the embedded processor calls the corresponding motion control algorithms for trajectory planning based on the command type: In point-to-point motion mode, it calculates the motor speed change curve according to the acceleration/deceleration curve (e.g., S-curve, trapezoidal curve) and determines the number of pulse outputs in each control cycle; In interpolation motion mode, it decomposes complex trajectories into multiple tiny line segments through interpolation algorithms and calculates the pulse allocation for each axis in each control cycle. The trajectory planning results are transmitted to the dedicated motion control chip, which generates high-precision pulse signals (A/B-phase or pulse + direction).
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5. Pulse Output & Motor Driving Stage: The pulse signals generated by the motion control chip are processed by a differential amplifier circuit and then transmitted to the servo or stepper motor drive through the pulse output channel. The drive drives the motor to operate according to the pulse frequency (corresponding to motor speed) and pulse number (corresponding to motor displacement). At the same time, the digital output channel of the control card can send auxiliary control signals such as enable and clamp to cooperate with motor motion to complete the entire control process.
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7. Position Feedback Acquisition & Closed-Loop Adjustment Stage: When the motor is running, the encoder (incremental or absolute) collects the motor rotor position information in real time and transmits the A/B-phase quadrature signal or SSI protocol signal to the feedback input channel of the control card. After the feedback signal is processed by isolation and shaping circuits, the motion control chip parses it into current position data and transmits it to the embedded processor. The processor compares the current position data with the target position data to calculate the position deviation. If the deviation exceeds the allowable range, it dynamically adjusts the pulse output frequency or number to achieve closed-loop position control, ensuring the motor runs accurately to the target position.
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9. I/O Interaction & Fault Handling Stage: The control card monitors the status of the digital input channels in real time, such as limit switch signals (triggered when the motor reaches the limit position) and emergency stop signals. When a limit or emergency stop signal is detected, the processor immediately sends a command to stop pulse output, cut off the motor enable, and report fault information to the upper computer via the PCI bus. The digital output channel sends corresponding control signals at specific nodes according to the motion process requirements (e.g., outputting a motor enable signal at the start of motion and a completion signal at the end of motion) to realize collaborative work with peripheral devices.

V. Common Faults & Solutions